Wool blend velour fabric

ABSTRACT

A wool blend velour fabric article ( 12 ) is formed of yarns ( 14, 16 ) consisting of wool fibers ( 17   a,    17   b ) in a blend with manufactured fibers ( 19   a,    19   b ) (i.e., synthetic and/or regenerated fibers). The wool and manufactured fibers are blended, i.e. spun, together in a manner to control the distribution of the wool fibers and of the manufactured fibers, across the cross-section of the yarn such that each of the wool fibers is generally surrounded by manufactured fibers, and thus shielded from interaction with other ones of the wool fibers. The resulting velour fabric article exhibits reduced shrinkage and felting.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit from U.S. Provisional Patent Application 61/296,100, filed Jan. 19, 2010.

TECHNICAL FIELD

This invention relates to wool blend velour fabrics, and more particularly to wool blend velour fabrics having minimal felting and shrinking

BACKGROUND

Velour is a fabric with a short, thick pile which makes the fabric soft to the touch. Velour is usually made of wool or cotton but can also be made from synthetic materials such as polyester. Generally a velour fabric made of wool will “felt” (i.e., the wool fibers will adhere and mat together through use and over time) and the fabric will have high shrinkage during the dyeing process and/or home laundering. It is known to overcome excess shrinkage and felting by treating the wool fibers chemically, e.g., by chlorination, or by ozonation, or by other oxidative process, all of which are environmentally unfriendly.

SUMMARY

In general, this invention relates to wool blend velour fabrics having minimal felting and shrinking

One aspect of the invention provides a wool blend velour fabric article that includes a fabric body having a technical face and a technical back. The fabric body having a velour surface formed at one or both of the technical face and the technical back. The velour surface is formed of yarn (e.g., a spun yarn) that includes a blend of wool and manufactured fibers (e.g., synthetic fibers such as polyester fibers, nylon fibers, acrylic fibers, modacrylic fibers, polyolefin, and polylactic acid, and/or regenerated fibers such as rayon fibers). The wool and manufactured fibers (i.e., synthetic and/or regenerated fibers) are blended across a cross-section of the yarn such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers.

Preferred implementations may include one or more of the following additional features and/or steps. The wool fibers can have an average diameter of 16 micron to about 36 micron, e.g., about 26 micron. In some embodiments, the wool fibers are not chemically treated by any oxidative process. The manufactured fibers can have an average thickness of less than 2 denier per filament. The blend includes at least 25 wt. %, e.g., at least 50 wt. %, of the manufactured fibers. In some cases, the manufactured fibers have flame retardant property. For example, the manufactured fibers may include modacrylic and/or flame retardant rayon. The wool fibers may be treated with flame retardant chemical.

Another aspect of the invention features a method of forming a wool blend velour fabric. the method includes joining a loop yarn and a stitch yarn to form a fabric prebody, the stitch yarn forming a technical face of the fabric prebody and the loop yarn forming a technical back of the fabric prebody; and finishing at least one of the technical face and the technical back of the fabric prebody to form a velour fabric body. At least one of the loop yarn and the stitch yarn includes a blend of wool and manufactured fibers. The wool and manufactured fibers are blended across a cross-section of the yarn such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers.

Preferred implementations may include one or more of the following additional features and/or steps. In some embodiments, both the loop yarn and the stitch yarn include blends of wool and manufactured fibers, and the wool and manufactured fibers are blended across respective cross-sections of the yarns such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers. In some embodiments, the fabric body is subjected to a dyeing process.

According to another aspect, a method of forming a velour fabric includes joining a yarn comprising a blend of wool and manufactured fibers (i.e., synthetic and/or regenerated fibers) to form a fabric prebody, the wool and manufactured fibers being blended across a cross-section of the yarn such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers; and finishing at least one surface of the fabric prebody to form a velour fabric body.

Preferred implementations may include one or more of the following additional features and/or steps. Methods can also include finishing the technical face and the technical back to form a double-face velour fabric body. In some embodiments, the fabric body is subjected to a dyeing process. Methods may optionally include finishing one of the technical face and the technical back to form a single face velour fabric body, e.g., having plaited jersey on one side.

In yet another aspect, a wool blend velour fabric article includes a fabric body having a technical face formed by a stitch yarn and a technical back formed by a loop yarn. The fabric body has a velour surface formed at one or both of the technical face and the technical back. One or both of the stitch yarn and the loop yarn comprises a blend of wool and manufactured fibers (i.e., synthetic and/or regenerated fibers). The wool and manufactured fibers are blended across a cross-section of the yarn such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers.

Preferred implementations may include one or more of the following additional features and/or steps. The wool fibers can have an average diameter of 16 micron to about 36 micron, e.g., about 26 micron. In some embodiments, the wool fibers are not chemically treated by any oxidative process. The manufactured fibers can have an average thickness of less than 2 denier per filament. The blend includes at least 25 wt. %, e.g., at least 50 wt. %, of the manufactured fibers. The stitch yarn may include elastomeric material (e.g., elastomer yarn and/or fibers). The manufactured fibers may have flame retardant property. For example, the manufactured fibers may include modacrylic and/or flame retardant rayon. The wool fibers may be treated with flame retardant chemical.

Embodiments can include one or more of the following advantages.

Forming a velour fabric from yarn that includes a blend of wool and manufactured fibers, where each wool fiber is generally surrounded by manufactured fibers, can help to shield the wool fibers from interacting with each other and, as a result, can help to inhibit felting and shrinking of the fabric.

Shielding the wool fiber from interaction with each other can also allow for the formation of a velour fabric without the use of environmentally unfriendly oxidative processes.

Other aspects, features, and advantages are in the description, drawings, and claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic end section view of a double-face fabric prebody.

FIG. 2A is a detailed cross-sectional view of a spun loop yarn.

FIG. 2B is a detailed cross-sectional view of a spun stitch yarn.

FIG. 3 is a somewhat diagrammatic perspective view of a double-face velour fabric article.

FIG. 4 is a perspective view of a segment of a circular knitting machine.

FIGS. 5A-5G are sequential views of a cylinder latch needle in a reverse plating circular knitting process.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

A wool blend velour fabric article is formed of yarns consisting of wool fibers in a blend with manufactured fibers (i.e., synthetic and/or regenerated fibers). The wool and manufactured fibers are blended, i.e. spun, together in a manner to control the distribution of the wool fibers and of the manufactured fibers, across the cross-section of the yarn, such that each of the wool fibers is generally surrounded by manufactured fibers, and thus shielded from interaction with other ones of the wool fibers. The resulting velour fabric article exhibits reduced shrinkage and felting.

FIG. 1, illustrates a fabric prebody 12 that is used to form the velour fabric article 10 (FIG. 3) of the invention. The fabric prebody is formed, e.g., in a knitting process, by joining a stitch yarn 14 and a loop yarn 16. The stitch yarn 14 forms the technical face 18 of the resulting fabric prebody 12 and the loop yarn 16 forms the opposite technical back 20, where it is formed into loops 22. The loop yarn 16 extends outwardly to overlie and cover the stitch yarn 14 at the technical face 18.

The loop yarn 16 forming the technical back 20 of the fabric body 12 is a spun yarn consisting of a blend of wool and at least 25 wt. % manufactured fibers. As illustrated in FIG. 2A, the wool and manufactured fibers 17 a, 19 a of the loop yarn 16 are spun (e.g., core-spun) together in a manner to control the distribution of the wool fibers 17 a and of the manufactured fibers 19 a, across the cross-section of the yarn such that each of the wool fibers 17 a is generally surrounded by manufactured fibers 19 a, and thus shielded from interaction with other ones of the wool fibers 17 a. The wool fibers 17 a of the loop yarn 16 have an average fiber diameter in the range of about 16 micron to about 36 micron, e.g., about 26 micron. Preferably, the wool fibers 17 a are not treated by chlorination, or by ozonation, or by any other oxidative processes. The manufactured fibers 19 a of the loop yarn 16 can be synthetic fibers (e.g., polyester, nylon, acrylic, modacrylic, polyolefin, and/or polylactic acid fibers) and/or regenerated fibers (e.g., rayon fibers). The manufactured fibers 19 a are relatively finer fibers having an average thickness of less than about 2 denier per filament.

As illustrated in FIG. 2B, the stitch yarn 14 forming the technical face 16 of the fabric body 12 can be also made of spun yarn consisting of a blend of wool and at least 25 wt. % manufactured (e.g., polyester, nylon, acrylic, modacrylic, polyolefin, polylactic acid, and/or rayon) fibers. As in the case of the loop yarn 16, the wool and manufactured fibers 17 b, 19 b of the stitch yarn 14 are distributed such that each of the wool fibers 17 b is generally surrounded by the manufactured fibers 19 b. The manufactured fibers 19 b shield the wool fibers 17 b from interaction with each other. The wool fibers of the stitch yarn 14 have an average fiber diameter in the range of about 16 micron to about 36 micron, e.g., about 26 micron. As in the case of the loop yarn 16, the wool fibers 17 b of the stitch yarn 14 are preferably left untreated by chlorination, or by ozonation, or by any other oxidative processes. The manufactured fibers 19 b have an average thickness of less than about 2 denier per filament.

Referring to FIGS. 4 and 5A-5G, the fabric prebody is formed (in a continuous web) by joining the stitch yarn 14 and the loop yarn 16 in a standard reverse plating circular knitting (terry knitting) process. This is principally a terry knit construction, where segments 23 of the loop yarn 16 cover the stitch yarn 14 on the technical face 18 and loops 22 of the loop yarn 16 form loops 22 at the technical back 20 of the fabric prebody 12.

The fabric prebody 12 is next subjected to finishing. During the finishing process, the technical face and technical back surfaces 18, 20, respectively, of the fabric prebody 12, with the segments 23 of loop yarn 16 overlying the stitch yarn 14 at the technical face surface 18 and the loops 22 formed at the technical back surface 20, are subjected to a finishing process, e.g., such as sanding, brushing and/or napping, to generate a velour 24, 26. The yarn fibers are raised at one or both surfaces of the fabric prebody 12, including the technical face 18 and the technical back 20, to form the velour 24, 26 at each face of the fabric body 30 of the double-face velour fabric article 10 (FIG. 3) of the invention.

The fabric article 10 may also be dyed, and heat may be applied to the fabric body, e.g. dry heat and/or wet heat, such as hot water or steam, e.g. during finishing or dyeing. Due at least in part to the construction of the individual yarns, and, in particular, the shielding of the wool fibers 17 a, 17 b (i.e., by the manufactured fibers 19 a,19 b) from interaction with each other, the velour fabric exhibits only minimal felting and shrinking as a result of exposure to wet heat (e.g., during the dyeing or finishing processes, and or regular home laundering).

Other Embodiments

While certain embodiments have been described above, other embodiments are possible.

As an example, while an embodiment has been described in which both the loop yarn and the stitch yarn consist of a spun yarn that includes a blend of wool and manufactured fibers, in some embodiments only the loop yarn or only stitch yarn includes such a spun yarn.

While a circular knit velour fabric has been described, in some embodiments the velour fabric can instead have warp knit construction.

Although an embodiment of a double-face velour fabric has been described in which both the technical face and technical back surfaces of the fabric are finished as velour, in some embodiments, only one of the surfaces (i.e., the technical back or the technical face) is finished as velour. As an example, the wool blend velour fabric can be finished as a single face velour and plaited jersey on one side, opposite the velour.

Although a reverse plating circular knitting process has been described, in some embodiments, the wool blend velour fabric can be produced by other methods of knitting or forming.

In some cases, the fiber blend may have flame retardant properties. For example, the manufactured fibers of the blend may include modacrylic and/or flame retardant rayon. Alternatively or additionally, the wool fiber can also be treated with flame retardant chemical.

In some embodiments, the stitch yarn can include elastomeric material (e.g., elastomer yarn and/or fibers) for enhanced stretch and recovery.

In some cases, the yarn comprising the blend of wool and manufactured fibers can be incorporated in a textile fabric having single jersey construction, double knit construction, or 3-end fleece knit construction.

Other embodiments are within the scope of the following claims. 

1. A wool blend velour fabric article comprising: a fabric body having a technical face and a technical back, the fabric body having a velour surface formed at one or both of the technical face and the technical back, wherein the velour surface is formed of yarn comprising a blend of wool and manufactured fibers, wherein the wool and manufactured fibers are blended across a cross-section of the yarn such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers.
 2. The wool blend velour fabric article of claim 1, wherein the wool fibers have an average diameter of 16 micron to about 36 micron.
 3. The wool blend velour fabric article of claim 1, wherein the wool fibers are not chemically treated by any oxidative process.
 4. The wool blend velour fabric article of claim 1, wherein the manufactured fibers are selected from the group consisting of polyester fibers, nylon fibers, acrylic fibers, modacrylic fibers, polyolefin, polylactic acid, and rayon fibers.
 5. The wool blend velour fabric article of claim 1, wherein the manufactured fibers have an average thickness of less than 2 denier per filament.
 6. The wool blend velour fabric article of claim 1, wherein the blend comprises at least 25 wt. % of the manufactured fibers, e.g. at least 50 wt. % of the manufactured fibers.
 7. The wool blend velour fabric article of claim 1, wherein the yarn is a spun yarn.
 8. The wool blend velour fabric article of claim 1, wherein the manufactured fibers have flame retardant property.
 9. The wool blend velour fabric article of claim 8, wherein the manufactured fibers comprise modacrylic and/or flame retardant rayon.
 10. The wool blend velour fabric article of claim 1, wherein the manufactured fibers comprise synthetic and/or regenerated fibers.
 11. The wool blend velour fabric article of claim 1, wherein the wool fibers are treated with flame retardant chemical.
 12. A method of forming a wool blend velour fabric, the method comprising: joining a loop yarn and a stitch yarn to form a fabric prebody, the stitch yarn forming a technical face of the fabric prebody and the loop yarn forming a technical back of the fabric prebody; and finishing at least one of the technical face and the technical back of the fabric prebody to form a velour fabric body, wherein at least one of the loop yarn and the stitch yarn comprises a blend of wool and manufactured fibers, wherein the wool and manufactured fibers are blended across a cross-section of the yarn such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers.
 13. The method of claim 12, wherein both the loop yarn and the stitch yarn comprise blends of wool and manufactured fibers, wherein the wool and manufactured fibers are blended across respective cross-sections of the yarns such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers.
 14. The method of claim 12, comprising finishing the technical face and the technical back to form a double-face velour fabric body.
 15. The method of claim 12, further comprising subjecting the fabric body to a dyeing process.
 16. The method of claim 12, comprising finishing one of the technical face and the technical back to form a single face velour fabric body.
 17. A method of forming a velour fabric, the method comprising: joining a yarn comprising a blend of wool and manufactured fibers to form a fabric prebody, the wool and manufactured fibers being blended across a cross-section of the yarn such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers; and finishing at least one surface of the fabric prebody to form a velour fabric body.
 18. The method of claim 17, further comprising subjecting the fabric body to a dyeing process.
 19. The method of claim 17, comprising finishing opposing surfaces of the fabric prebody to form a double-face velour fabric body.
 20. The method of claim 17, comprising finishing one of the technical face and the technical back to form a single face velour fabric body.
 21. The method of claim 17, comprising: joining a yarn comprising a blend of wool and manufactured fibers to form a fabric prebody having a plaited construction; and finishing one of the technical face and the technical back to form a plaited single face fabric.
 22. A wool blend velour fabric article comprising: a fabric body having a technical face formed by a stitch yarn and a technical back formed by a loop yarn, the fabric body having a velour surface formed at one or both of the technical face and the technical back, wherein one or both of the stitch yarn and the loop yarn comprises a blend of wool and manufactured fibers, wherein the wool and manufactured fibers are blended across a cross-section of the yarn such that each wool fiber is generally surrounded by manufactured fibers and thereby shielded from interaction with other ones of the wool fibers.
 23. The wool blend velour fabric article of claim 22, wherein the wool fibers have an average diameter of 16 micron to about 36 micron.
 24. The wool blend velour fabric article of claim 22, wherein the wool fibers are not chemically treated by any oxidative process.
 25. The wool blend velour fabric article of claim 22, wherein the manufactured fibers are selected from the group consisting of polyester fibers, nylon fibers, acrylic fibers, modacrylic fibers, polyolefin, polylactic acid, and rayon fibers.
 26. The wool blend velour fabric article of claim 22, wherein the manufactured fibers have an average thickness of less than 2 denier per filament.
 27. The wool blend velour fabric article of claim 22, wherein the blend comprises at least 25 wt. % of the manufactured fibers, e.g. at least 50 wt. % of the manufactured fibers.
 28. The wool blend velour fabric article of claim 22, wherein the yarn is a spun yarn.
 29. The wool blend velour fabric article of claim 22, wherein the stitch yarn comprises elastomer yarn and/or fibers.
 30. The wool blend velour fabric article of claim 22, wherein the manufactured fibers have flame retardant property.
 31. The wool blend velour fabric article of claim 30, wherein the manufactured fibers comprise modacrylic and/or flame retardant rayon.
 32. The wool blend velour fabric article of claim 22, wherein the manufactured fibers comprise synthetic and/or regenerated fibers.
 33. The wool blend velour fabric article of claim 22, wherein the wool fibers are treated with flame retardant chemical. 